Waeco Waeco ASC 5100 G Operating instructions

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copyright and design law. The underlying technical design and the products contained herein may

be protected by design, patent or be patent pending. The trademarks mentioned in this manual

belong to Dometic Sweden AB. All rights are reserved.

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EN

57

ASC 5100G

Contents

1 About this operating manual. . . . . . . . . . . . . . . . . . . . . . . . . . .59

1.1 Hotline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

1.2 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

2 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

2.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.2 Operating the device safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

2.3 Handling refrigerant safely. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.4 Operational measures when using the unit . . . . . . . . . . . . . . . . . . . . . . 64

2.5 Warnings on the AirCon Service Center . . . . . . . . . . . . . . . . . . . . . . . . . 65

2.6 Safety devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

4 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

5 Proper use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

6 Overview of the AirCon Service Center. . . . . . . . . . . . . . . . . . .68

6.1 Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

6.2 Rear and side view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

7 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

7.1 Setting up and switching on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

7.2 Standby menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

7.3 Language selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

7.4 Entering company data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

7.5 Entering the date and time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

7.6 Editing default values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

7.7 Using a container for oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

7.8 Filling up the internal refrigerant container . . . . . . . . . . . . . . . . . . . . . . 76

8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

8.1 Shutdown in case of repair, emergencies and malfunctions . . . . . . . . . 78

8.2 Short selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

8.3 User codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

8.4 Creating a personal database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

8.5 Transferring the consumption of refrigerant onto a USB stick . . . . . . . . 84

8.6 Showing the refrigerant consumption on the display . . . . . . . . . . . . . . . 86

8.7 Air conditioning system test without refrigerant service. . . . . . . . . . . . . 88

8.8 Free selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

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ASC 5100G

58

9 Service tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

9.1 Leak test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

9.2 Changing the dryer filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

9.3 Filter maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

9.4 Calibrating the pressure transducer . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

9.5 Changing the vacuum pump oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

9.6 Meter readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

9.7 Updating the software via USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

10 Cleaning and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .105

11 Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

11.1 Disposing of used fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

11.2 Disposing of packaging material . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

11.3 Disposal of the old unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

13 Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

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ASC 5100G About this operating manual

1 About this operating manual

This operating manual describes the ASC 5100G air conditioning service

station (AirCon Service Center).

The manual is for those who perform maintenance on vehicle air condi-

tioning systems and have the expertise required to do so.

It contains all the instructions necessary for safe and effective operation

of the air conditioning service station. Before starting the air conditioning

service unit for the first time, read this operating manual carefully.

Please also note the information in the current material safety data

sheets. They can be found at:

dometic.com/sds

Keep this operating manual in the compartment of the

AirCon

Service Center, so that any information you need is always at

hand.

1.1 Hotline

If you need more information on the AirCon Service Center that is not

contained in this manual, please contact the

hotline (tel.: +49 (0) 2572 879-0)

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About this operating manual ASC 5100G

60

1.2 Explanation of symbols

!

A

I

WARNING!

Safety instruction: Indicates a hazardous situation that, if not avoided,

could result in death or serious injury.

CAUTION!

Safety instruction: Indicates a hazardous situation that, if not avoided,

could result in minor or moderate injury.

NOTICE!

Indicates a situation that, if not avoided, can result in property damage.

NOTE

Supplementary information for operating the product.

Format Meaning Example

Bold Designations used on the unit Press ENTER to confirm.

“Bold” Display messages “Short selection”

 Text

List in any order

 Pressure monitor

 Pressure relief valves

1. Text

2. Text

3. Text

Actions to be carried out in the

order shown

1. Connect the unit.

2. Switch on the unit.

3. Press the selection button.

✓ Text

Result of an action

✓ Unit is ready for operation.

Text (1) Part numbers referring to the

overview (

page 68 and

page 69).

Use the keypad (2) to enter the

data.

Text (A) Part designations which refer to

the diagrams shown in the sec

-

tion describing the work step

Remove the filter cartridge (E)

on the left side.

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ASC 5100G Safety

2 Safety

The manufacturer accepts no liability for damage in the following cases:

 Damage to the product resulting from mechanical influences and

incorrect connection voltage

 Alterations to the product without express permission from the

manufacturer

 Use for purposes other than those described in the operating manual

2.1 General safety instructions

!

WARNING!

 Observe national work safety regulations.

 Observe the safety instructions in this operating manual.

 The AirCon Service Center may only be used by personnel who are

able to demonstrate the appropriate specialist training and are

familiar with the operation and basic principles of the

AirCon Service Center, of air conditioning systems and of refrigerants.

 The AirCon Service Center may only be repaired by personnel

authorized by Dometic.

 Only use the device for its intended purpose.

!

CAUTION!

 Do not make modifications to the AirCon Service Center.

 Do not carry out maintenance work on the vehicle air conditioning

system when the engine is at operating temperature.

When performing maintenance on the vehicle air conditioner, the

surface temperature of attachment parts or surrounding parts must

be less than 405

°C.

 Risk of injury from bursting components if the permitted

temperature limits are exceeded

Only transport the AirCon Service Center without refrigerant to avoid

excess pressure.

 The AirCon Service Center may not be stored outdoors.

 Store the service hoses in the hose pocket on the back when the

AirCon Service Center is not in use.

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Safety ASC 5100G

62

2.2 Operating the device safely

!

WARNING!

 Do not operate the AirCon Service Center in areas where there is a

risk of explosion (for example, battery charging rooms or spraying

booths), see operating safety directive BGR 157/TRG 250, 280, 316.

 Do not pump compressed air into the refrigerant lines of the

AirCon Service Center or the vehicle air conditioning system. A mix-

ture of compressed air and refrigerant can be flammable or explosive.

 Risk of injury due to unplanned or unintended switching on of

the air conditioning service unit

Switch off the AirCon Service Center prior to all maintenance work and

disconnect the mains cable from the mains supply. Pull the plug from

the socket or from the AirCon Service Center.

 Risk of burns from cold or hot components

Wear protective gloves.

!

CAUTION!

 Do not start up the AirCon Service Center if it is damaged.

 Each time you start up the unit or top up the AirCon Service Center,

first check whether the unit and all the service hoses are undamaged

and that all valves are closed.

 Lay the service hoses in such a way that they pose no tripping hazard

for other persons.

 Serious injuries due to overturning or falling load

The handle is not used to lift the unit. Only push the

AirCon Service Center on rollers to transport it.

 Always position the unit on level ground and secure the front wheels.

 Only use approved refrigerant vessels with safety valves to refill the

AirCon Service Center.

 Always use the main switch of the AirCon Service Center to switch it

on and off. Do not leave the device unattended when it is switched on.

 Risk of injury from leaking fluids

Leaking fluids on the floor can cause persons to slip and injure

themselves.

Wipe up leaked or dripped fluids immediately or absorb them with a

suitable binding agent.

Dispose of them in an environmentally sound manner.

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ASC 5100G Safety

A

NOTICE!

 Never expose the unit to heavy moisture.

 Do not operate the unit outdoors when it is raining.

 Do not operate the unit near heat sources (such as heaters) or in

direct sunlight.

 Only use R-1234yf refrigerant. If other refrigerants are mixed in, this

can damage the AirCon Service Center and the vehicle air condition-

ing system.

 Before you shut down the AirCon Service Center, make sure that the

selected program has ended and that all valves are shut. Otherwise

refrigerant can leak.

 When you modify values in the menus, always compare them with the

specifications on the vehicle.

 When parking, use the brake lever on the front wheels to secure the

AirCon Service Center from rolling away.

2.3 Handling refrigerant safely

!

WARNING!

 Do not carry out maintenance work on the vehicle air conditioning

system when the engine is at operating temperature.

When performing maintenance on the vehicle air conditioner, the

surface temperature of attachment parts or surrounding parts must

be less than 405 °C.

!

CAUTION!

 Wear personal safety equipment (safety goggles and protective

gloves) and avoid coming into contact with the refrigerant. Contact

with the refrigerant draws out body heat and the affected areas can

freeze.

 Do not inhale refrigerant vapor. Although the vapor is non-toxic, it

displaces the oxygen you need to breathe.

 Only use the device in well-ventilated areas.

 Refrigerant may not be used in low-lying spaces such as assembly

pits or soakaways. Refrigerant is heavier than oxygen and therefore

displaces the air you need to breathe. This can cause a lack of oxy-

gen when working in unventilated assembly pits.

A

NOTICE!

 Make sure that refrigerant is not able to escape and leak into the

environment during operation, when filling or draining refrigerant or

during repair and service work.

This will protect the environment.

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Safety ASC 5100G

64

It also avoids the difficulty or impossibility of detecting leaks in the

vehicle or in the unit due to the presence of refrigerant in the vicinity

of the AirCon Service Center.

 Take suitable precautions to ensure that leaking refrigerant is not able

to get into the drainage system.

I

NOTE

 Special information on refrigerant R-1234yf and safety measures as

well as the protection of personnel and objects, including fire protec-

tion, can be found in the safety sheets of the refrigerant manufacturer.

2.4 Operational measures when using the unit

The operator must provide operating instructions according to TRG 402

for each filling system (AirCon

Service Center). These operating instruc-

tions must be used to train personnel in handling the unit.

The operator must ensure that personnel are instructed in the following

points at least once a year:

 Special dangers when dealing with compressed gases

 Safety guidelines when dealing with compressed gases

 Health precautions when dealing with compressed gases

 Operating the unit and performing service work on the unit

The operator must ensure that personnel appointed to perform service

and repair work as well as leak inspections are certified to deal with

refrigerant and filling systems.

Certification and knowledge of the applicable guidelines and standards

can be acquired from a training course at a chamber of trade, chamber of

industry and commerce or at any other recognized training facility.

The system operator must ensure that all service hoses are laid in such

a way that they cannot be damaged when the unit is used.

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ASC 5100G Safety

2.5 Warnings on the AirCon Service Center

Only connect the unit to a socket with 230 V / 50 Hz AC.

Protect the unit against rain!

Wear gloves when handling refrigerants!

Wear goggles when handling refrigerants!

Flammable substances warning

2.6 Safety devices

 Pressure monitor: switches the compressor off if normal operating

pressure is exceeded.

 Pressure relief valve: additional safety mechanism to protect lines or

vessels from bursting if the pressure continues to rise despite the

safety pressure monitor.

 Fan monitor: continuously checks whether the rear fan circulates

sufficient air.

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Scope of delivery ASC 5100G

66

3Scope of delivery

The AirCon Service Center and its accessories are carefully checked

before shipping.

The AirCon Service Center was tested for leaks before shipping.

After delivery, check that all the parts listed below are present and

undamaged.

If any parts are missing or damaged, notify the company responsible for

transport immediately.

A

Description Ref. no.

Adapter for 500 ml fresh oil bottle 4440600026

Oil bottle, 250 ml 4440600034

Adapter for coolant bottles (large connection) 4440600148

Sample bottle for professional oil can (Daphne Hermetic

oil), 100

ml

Waste oil receptacle 250 ml 4440600249

Goggles/gloves 4445900107

Operating manual

NOTICE!

For safe operation and calibration, you require R-1234yf refrigerant (not

in scope of delivery).

Refrigerant vessels are currently supplied with various connecting

threads and adapters; these are not in the scope of delivery.

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ASC 5100G Accessories

4 Accessories

Available as accessories (not included in the scope of delivery):

5 Proper use

The ASC 5100G AirCon Service Center (item number: 9103301878) is

designed for performing maintenance on vehicle air conditioning

systems. The unit is designed for commercial use.

The AirCon Service Center may only be operated by personnel who have

the expertise required for servicing air conditioning systems.

This AirCon Service Center may only be used to service vehicle air

conditioning systems in which R-1234yf refrigerant is used. Other

refrigerants are not permitted.

The AirCon Service Center is only suitable for approved operating fluids.

Description Ref. no.

Replacement filter 4440400009

Protective unit cover 4445900081

Safety goggles 8885400066

Protective gloves 8885400065

Vacuum pump oil (1000 ml) 8887200018

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Overview of the AirCon Service Center ASC 5100G

68

6 Overview of the AirCon Service Center

6.1 Front

1 Display

2 Keypad

3 Low pressure gauge

4 High pressure gauge

5 Front cover

6 Front wheels with wheel stops

7 Service hose for low pressure connection (blue)

8 Service hose for high pressure connection (red)

9 USB port

1 2

6

5

4

8

7

9

3

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ASC 5100G Overview of the AirCon Service Center

6.2 Rear and side view

10 Container for fresh oil

11 Drained oil receptacle

12 Main switch

13 Fan

11

10

13

12

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Initial start-up ASC 5100G

70

7 Initial start-up

7.1 Setting up and switching on

1. Drive the AirCon Service Center to the workplace.

2. Lock the front wheels (6).

I

3. Connect the AirCon Service Center to the mains.

4. To switch it on, set the main switch (12) to I.

The switch-on delay runs for 35 seconds and the housing is venti-

lated. The software version number then appears in the display (1)

for several seconds:

“SW”: Software status

“DB”: Database

“SN”: Serial number

“LF”: Language file

✓ When the start-up procedure is complete, the AirCon Service Center

displays the following:

I

NOTE

During operation, the unit must be on a level, flat surface so that

measurements can be made correctly.

WAECO INTERNATIONAL

ASC5100G SW 5ELU0076

DB ldyf1701

SNxxxxxx LF 12340061

Refrigerant g. XXXX

11:56:35 10/03/17

NOTE

Ignore any error codes which occur during commissioning (see

page 108) and skip by pressing ENTER.

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ASC 5100G Initial start-up

7.2 Standby menu

The standby menu shows you the current supply quantities and the time

settings of the AirCon Service Center.

The following information is shown:

 Refrigerant quantity

 Time

 Date

7.3 Language selection

1. Press the cursor keys  or  to access the basic menu.

2. In the basic menu, use the cursor keys  or  to select “Other

selections”:

3. Press ENTER to confirm.

4. Use the cursor key  to select “Service”.

5. Press ENTER to confirm.

6. Enter the password “5264”.

7. Use the cursor keys  or  to select the preferred language.

8. Press ENTER to confirm.

9. Press STOP. The language chosen is active and the standby menu

is displayed.

Short selection

Free selection

Other selections

ENTER-OK

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Initial start-up ASC 5100G

72

7.4 Entering company data

The company data is displayed in the service log.

1. In the basic menu, use the cursor keys  or  to select “Other

selections”:

2. Press ENTER to confirm.

3. Use the cursor key  to select “Service”.

4. Press ENTER to confirm.

5. Enter the password “3282”.

6. The company data is shown in the third line of the display (1).

You can enter five lines, each with up to 20 characters.

The display shows the number of lines of company data after the

message “Enter company data” (“01” to “05”).

Use the cursor keys  or  to select the line of company data you

want.

7. Use the keypad (2) and the cursor keys to enter the data.

To switch between upper and lower case, press the Info key .

To delete a character, briefly press the C key.

To delete the current line, press and hold down the C key.

8. Press ENTER to confirm.

9. Press STOP. The set data is activated.

10. Press STOP again to access the standby menu.

Short selection

Free selection

Other selections

ENTER-OK

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ASC 5100G Initial start-up

7.5 Entering the date and time

Date and time are required for logging of the service procedures.

1. In the basic menu, use the cursor keys  or  to select

“Other selections”:

2. Press ENTER to confirm.

3. Use the cursor key  to select “Service”.

4. Press ENTER to confirm.

5. Enter the password “8463”.

6. Use the keypad and the cursor keys to enter the information.

7. Press ENTER to confirm.

8. Press STOP to access the standby menu.

Short selection

Free selection

Other selections

ENTER-OK

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Initial start-up ASC 5100G

74

7.6 Editing default values

The AirCon Service Center has preset values for the most important ser-

vice tasks. The default values appear automatically when you select the

respective menu.

You can alter the following default values if necessary:

1. In the basic menu, use the cursor keys  or  to select “Other

selections”:

2. Press ENTER to confirm.

3. Use the cursor key  to select “Service”.

4. Press ENTER to confirm.

5. Enter the password “7388”.

6. Use the keypad and the cursor keys to enter the information.

7. Press ENTER to confirm.

8. Press STOP to access the standby menu.

Parameter Default value

Pressure increase test time min. 5

Vacuum time min. 20

Leak test min. 4

PAG oil ml. (additional quantity) 0

Filling Qt. g. 500

Display logo? Yes

Short selection

Free selection

Other selections

ENTER-OK

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ASC 5100G Initial start-up

7.7 Using a container for oils

I

1. Push the containers into the snap locks:

– Container for fresh oil (10)

– Drained oil receptacle (11)

NOTE

Only use oils approved for R-1234yf. Observe the manufacturer's

instructions.

11

10

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